Method and machine for simultaneous and parallel production of similar products, through straightening and bending of wires, wire rods, metal tubes or other material of prismatic cross section

ABSTRACT

The present invention refers to a method and a machine for simultaneous and parallel production of similar products by wires, wire rods, tubes or other material of prismatic cross section, which is characterised by existence of more than one production lines, which operate in parallel, and which consist of similar mechanisms for straightening and bending of the material, similar mechanisms for changing of the bending plane, and for cutting of the final parts. All the straightening mechanisms are driven by a common motor, through a common driving mechanism, all the bending mechanisms are driven by a common motor, through a common driving mechanism, all the mechanisms for the changing of the bending plane are also driven by a common motor, through a common driving mechanism, and all the cutters are driven by a common power source. All the operation of the motors and of the driving mechanisms are controlled and programmed by one common controlling unit.

The present invention refers to a method and a machine for simultaneous and parallel production of similar products, by straightening and bending mechanisms. The supplied material is wire, wire rod or any other material of prismatic cross section, and it is fed simultaneously at several production lines, where controlling and driving is common.

The products are widely used in the construction of machine parts, of various consumer products made of wire, of products made of wire rods, and of parts made of metal tubes.

The machines, which are available in the market, consist of one straightening and one feeding mechanism, which straighten and advance the wire respectively, and of one bending mechanism, for bending at a single plane (2-D) or at multiple planes (3-D). Each mechanism disposes its own independent motor, its own means for measuring of length or rotation angle, and its own means for transferring of motion from the motor towards each particular mechanism. Furthermore, the machine disposes a central computer for programming (planning) of the production parts and for controlling of the various mechanisms motion.

Any competitors' machines exhibit the above characteristics but they differ from each other with respect to the straightening method, the advancement mechanism, and the bending mechanism.

Starting from the supplied material, each machine constructs products in a serial mode, one after the other. The need for high productivity leads to the construction of very fast machines, which operate at high speeds, and hence they have particular requirements of robustness, housing, construction material, and high-speed electronic controllers. As a direct consequence of this, the resulting machines are very complicated and particularly expensive.

As an example, the only way for doubling the production in a given production line, is by introduction of another similar machine, which disposes all the mechanisms, motors and electronics parts, which were mentioned previously. This is an expensive solution, since it requires procurement of another machine.

The objective of the present invention is to present a method, which will resolve the problems of the existing methods, and will lead to the construction of a simple-in-design, low-cost, and high-productivity machine.

The aim of the present invention is to describe a machine, which implements the method of the invention, where the machine exhibits high productivity at lower production cost, less machine bulk, and fully automated operation.

The method is schematically presented in FIG. 1. The wire (1) is pulled from a reel, where it is stored, and is fed towards the straightening mechanism (4) through the advancement mechanism (3). Advancement is usually implemented through roller pairs, which press the wire, rotate, and therefore advance it. The advancement rollers move through the mechanisms (16), which are driven by the motor (13). By controlling the motor, the advancement of the material (1) is also controlled.

Consequently, the material (1) advances to the bending mechanism (6), where it is bent, through rotation of a moving pin, about a fixed pin. The bending angle depends on the operation of the motor (15), which drives the rotating pin, through the mechanism (18). When production of each part is completed, the material (1) is cut by a cutter, located near the bending mechanism.

The operation plane of the bending mechanism (5), which is defined by the fed and the bent wire, can be changed upon rotation with respect to the axis of the longitudinal wire (1), through the mechanism (17), which is driven by the motor (14).

After production of a part is completed, a cutter (21) cuts and separates the part from the remaining material.

The advancement, straightening, bending and change of bending plane mechanisms are driven by motors, through appropriate mechanisms, where the referred motors are controlled and driven by a central controlling unit (19). A terminal is used as an interface between the controlling unit and the user, where all programming is implemented.

The material (2) is being processed simultaneously with the material (1), where the material (2) is fed through the advancement mechanism (8), is straightened through the straightening mechanism (9), is bent through the bending mechanism (11), is rotated for 3-D bending through the mechanism (10), and is cut after production of the part is completed through the cutter (22).

According to the present invention, the advancement mechanism (8) of the material (2) is similar to the advancement mechanism (3) of the material (1), and they are driven by the same motor (13), through a common driving mechanism (16).

Furthermore, the straightening mechanisms (4) and (9) are similar. Similar are also the bending mechanisms (6) and (11) for the materials (1) and (2) respectively, which are driven by a common motor (15), through a common driving mechanism (18).

The mechanism (5) for the changing of the bending plane in space for the material (1) is similar to the mechanism (11) for the material (2), and they are driven by a common motor (14), through common driving mechanism.

The two cutters (21) and (22) in the two production lines are similar and they are driven by a common driving source.

The controlling unit (19) remains the same for both production lines, and the number of controlled rotation axes is also the same. Similarly, the terminal unit, which is used for communication with the user (20), is common for both production lines.

According to the present invention, more production lines can be added to the above two-line system, where all production lines have similar mechanisms, where these mechanisms dispose common driving motors and driving mechanisms. Furthermore, all production lines have a common controlling unit and a common terminal for communication with the user.

More details about the method and the machine according to the present invention will be better comprehended during the description of the following particular implementation. The machine is described in the attached figures, in the sense of a non-restrictive example.

FIG. 1 presents the method of the present invention.

FIG. 2 presents a side view of the machine.

FIG. 3 presents a top view of the machine.

For simplicity, the machine (FIG. 2, FIG. 3), which realizes the method of the present invention is presented below with two production lines. The invention refers to two or more similar production lines, which produce similar parts, disposing common driving motors and driving mechanisms for the machine various mechanisms.

The wire (1) is fed through the roller couples (30) of the advancement mechanism (3), which are driven by the shaft (31), through the chain (32). The wire (2) is fed through the roller couples (33), which are driven by the same shaft (31), through the chain (34). The shaft (31) is rotated by the motor (13), through the chain (35), where the motor (13) is a servomotor controlled by the controller (19).

Consequently, the wires (1) and (2) are fed towards the straightening mechanism (4) and (9) respectively, for straightening of the wires. In this case, the straightening mechanism comprises of a two-level straightening.

The straightened wire (1) is fed towards the mechanism (5) for the selection of the bending plane, which consists of a fixed gripper (36) and a rotating gripper (37), where the axis of rotation of the gripper (37) coincides with the axis of the wire (1).The rotating gripper (37) is driven by the servomotor (14), through the chain (38), where the servomotor (14) is controlled by the system controller (19). In the second production line for the wire (2), similar mechanisms are in operation, namely a fixed gripper (39) and a rotating gripper (40). The rotating gripper (40) is driven by the same motor (14), through the chain (41).

The change in the bending plane is implemented as following: The fixed (36) and the rotating (37) grippers are activated and constrain firmly the wire (1), and the fixed (39) and rotating (40) grippers are activated and constrain firmly the wire (2). Then, the motor (14) drives the rotating grippers (37) and (40), which rotate the wires (1) and (2) respectively about the fixed grippers. The torsional deformation of the two wires causes the rotation of the semi-formed products (7) and (12), with respect to the fixed parts of the wires. The rotation of the wires causes permanent plastic deformations due to torsion, thus producing 3-D geometries of products.

Consequently, the wire (1) is advanced towards the bending mechanism (6), which consists of a fixed pin (41) and a rotating pin (42), which rotates about the fixed pin (41). The rotating pin is supported on a shaft, and is driven by a shaft (44), through the cogged belt (43). The shaft is driven by the servomotor (15), which is controlled by the controller (19). Simultaneously, the wire (2) is advanced towards the bending mechanism (11), which consists of a fixed pin (45) and a rotating pin (46). The rotating pin is supported on a shaft, and is driven by the common shaft (44), through the cogged belt (47). The shaft is driven by the common servomotor (15). Upon activation of the rotor (15), the pins (42) and (46) are rotated about the fixed pins (41) and (45) respectively, and bend the wires, moving along the under production parts (7) and (12).

The cutter (21) cuts the wire (1) after completion of each part in the first production line. The cutter consists of a moving cutting tool (48), which is driven by a hydraulic cylinder with respect to a fixed cutting tool (49), and finally cuts the material (1). A similar cutter operates in the second production line, where the two cutters (21) and (22) share a common source of high-pressure oil system.

The machine operation is programmed through a communication terminal (20), the operation of the servomotors and consequently the motion of each mechanism is controlled by a controller (19). These mechanisms are the advancement of the wires, the selection of the bending plane and the wire bending.

In the case of a machine of the present invention that can only perform bending on one plane and not 3-D bending, the mechanisms (5) and (10) for changing the bending plane, and the motor (14) transmission mechanisms are omitted.

The 3-D bending mechanism can be of different construction. For example, the bending mechanisms (6) and (11) can be rotated about the axes of the wires (1) and (2) respectively, in order to obtain the changing of the bending plane.

The straightening mechanisms (4) and (9) can be of the two plane type or can be of the rotor type.

The present invention is characterised by the simultaneous straightening and bending of a large number of similar wires, on a large number of similar production lines, where similar products are produced.

Furthermore, it is characterised by the common driving of similar mechanisms by a common servomotor, and by the existence of one common controller and one terminal unit for communication by the user.

The machine of the present invention exhibits the following advantages: When, for example, the machine operates with three feeding lines, it has the same production capacity with three independent machines, operating at the same speed. The machine is much cheaper, due to common motors, mechanisms and controller. The machine occupies less space.

The invention leads to the construction of a machine, which can maintain high production capacity, due to existence of more than one wire-feeding lines, even during operation at lower speeds. 

1. A method for simultaneous and in parallel production of similar products, through straightening and bending of wires, wire rods, tubes or any other material of prismatic cross section, which is characterized by production lines, consisting of an advancing mechanism (3) and a straightening mechanism (4) for the material (1), where the material is advanced and straightened by, respectively, of a bending mechanism (6), where the material is subjected to pre-programmed bendings, where the bending plane can be changed, through the mechanism (5), and of a cutter (21) for the cutting of the material, after each part is concluded, and which is characterised by the existence of more than one similar production lines, which produce similar products, and by the existence of similar mechanisms, driven by common motors and common driving mechanisms for all production lines, such as the advancement mechanisms (3), (8) etc., which are all driven by a common motor (13), through common driving mechanisms (16), the bending mechanisms (6), (11) etc., which are all driven by a common motor (15), through common driving mechanisms (18), the mechanisms for the changing of the bending plane (5), (10) etc., which are all driven by a common motor (14), through common driving mechanisms (17), and the cutters (21), (22) etc., which are all driven by a common power source, and which is characterised by the existence of one central controller (19) for controlling motor operation, and of one terminal station (20) for communication between machine and user and for the machine programming.
 2. A method for simultaneous and in parallel production of similar products, through straightening and bending of wires, wire rods, tubes or any other material of prismatic cross section, according to claim 1, which is characterized by the existence of more than two similar feeding lines (1), (2) etc., which advance (3), (8) etc., and straighten (4), (9) etc., the material and are driven by a common source (13), and by respective bending units (6), (11) etc., which perform 2-D bending of the material, and which are driven by a common source (15), and by cutters (21), (22) etc. for the cutting of the material, which are all driven by a common power source, and which is characterised by the existence of one central controller (19) for controlling motor operation, and of one terminal station (20) for communication between machine and user and for the machine programming.
 3. A machine for simultaneous and in parallel production of similar products, through straightening and bending of wires, wire rods, tubes or any other material of prismatic cross section, which is characterized by production lines, consisting of an advancing mechanism (3) and a straightening mechanism (4) for the material (1), where the material is advanced and straightened by, respectively, of a bending mechanism (6), where the material is subjected to pre-programmed bendings, where the bending plane can be changed, through the mechanism (5), and of a cutter (21) for the cutting of the material, after each part is concluded, and which is characterised by the existence of a common motor (13) driving a common shaft (31) for the advancement of all materials (1), (2) etc., towards the advancement mechanisms (3), (8) etc., through the roller couples (3), (8) etc., which are driven be the chains (32), (34) etc., by the existence of a common motor (15) driving a common shaft (31) for the changing of the bending plane, which is performed at the mechanisms (5), (10) etc., through the chains (38), (41) etc., by the existence of a common motor (14) driving a common shaft (44) for the bending of the wires (1), (2) etc., on the bending mechanisms (6), (11) etc., where the rotating pins (42), (46) etc., bend the materials around the fixed pins (41), (45) etc., through the belts (43), (47) etc., by the existence of a common power source for driving the moving cutting tool on the fixed tool of the cutters (21), (22) etc., for the cutting of each part (7), (12) etc., after its production is completed, and which is characterised by the existence of one central controller (19) for controlling motor operation, and of one terminal station (20) for communication between machine and user and for the machine programming. 